CN106193517B - 无机材质复合地板 - Google Patents
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Abstract
无机材质复合地板,涉及一种复合地板,包括胶体层和设置在所述胶体层上的树皮层,所述的胶体层由发泡沫玻璃碎块做为基体、发泡硫氧镁水泥为作为浆体胶结而成。与现有技术相比,本复合地板具有与木质地板相同的质感与脚感,还具有优良的弹性,行走在上面时柔和无噪音,同时还具有木质地板不具有的耐水性、不燃性、无毒性、耐久性等特点。
Description
技术领域
本发明涉及一种复合地板,尤其是一种无机材料复合地板。
背景技术
现有生产和应用的地板主要分为实木地板、实木复合地板和强化地板这三种,另外还有小部分的竹地板和其他材料复合具有特殊作用的复合地板。主流的地板既实木、实木复合、强化这三类都是使用整体木材、片状木材、碎颗粒木材作为原料制造,这种类型的地板均不符合当今中国绿色发展的理念,需要耗费非常多的森林资源并使用有毒的胶黏剂。尤其是强化地板,因为在强化地板的生产过程中会大量采用有机粘结剂,铺装在室内后通常会释放甲醛等有害气体,污染环境,影响人体健康。另一方面,木质地板怕水、怕火,一旦遇水浸泡就会失去使用功能;一旦遇火会变为助燃物,危及室内人员安全以及加速建筑燃烧损毁。
发明内容
本发明针对现有技术中的不足,提供了一种无机材质复合地板以及其制作方法,本复合地板具有与木质地板相同的质感与脚感,还具有优良的弹性,行走在上面时柔和无噪音,同时还具有木质地板不具有的耐水性、不燃性、无毒性、耐久性等特点。
为了解决上述技术问题,本发明通过下述技术方案得以解决:无机材质复合地板,包括胶体层和设置在所述胶体层上的树皮层,所述的胶体层由发泡玻璃碎块做为基体、发泡硫氧镁水泥为作为浆体胶结而成。
上述技术方案中,优选的,所述的树皮层厚度在0.3mm~0.6mm之间。
一种无机材质复合地板制作方法,包括以下几个步骤,步骤A):以重量百分比计,将含有至少80%Na2O·CaO·6SiO2复合硅酸盐的玻璃进行研磨,研磨后得到细度不小于200目的复合硅酸盐粉末,将碳酸盐进行研磨,研磨后得到细度不小于200目的碳酸盐粉末;步骤B):以质量百分比计,将95%~97%的复合硅酸盐粉末,3%~5%的碳酸盐粉末混合成原料粉末,在800℃至850℃之间对原料粉末进行加热,原料粉末在加热过程中由粉状固相转变成熔融状的液相形成熔融玻璃体,在此过程中熔融玻璃体会释放CO2气体,当熔融玻璃体CO2气体释放完后进行冷却,在冷却的过程中熔融玻璃体开始固化成多孔状态的泡沫玻璃体,把泡沫玻璃体破碎后得到颗粒容重为250kg/m3~350kg/m3、颗粒直径5mm~50mm的泡沫玻璃碎块;步骤C):以质量份计,将60份~70份轻烧氧化镁,30份~40份波美度在25°Be'~30°Be'之间的硫酸镁混合成硫氧镁水泥浆,然后在通入空气的情况下往硫氧镁水泥浆内添加2份~3份十八烷基磺酸钠形成容重为600kg/m3~700kg/m3的硫氧镁水泥浆体;步骤D):在板状模具中放入泡沫玻璃碎块,然后注入硫氧镁水泥浆体,干燥后形成胶体层;步骤E):在胶体层上附着树皮层形成复合地板。
上述技术方案中,优选的,在步骤B中,所述泡沫玻璃碎块容重为300kg/m3。
上述技术方案中,优选的,在步骤C中,硫氧镁水泥浆体容重为650kg/m3。
本发明复合地板的基体是泡沫玻璃碎块,然后通过发泡硫氧镁水泥作为填充剂以及结合剂。这种复合地板不仅具有良好的弹性和强度,还具有非常好的抗撞击、耐水、耐火性能。相比市面上的主流木质地板,本发明采用无机材料作为基体,与现有木质地板材料以及加工工艺本质不同,但性能和质感不差于木质地板。本复合地板由泡沫玻璃碎块与发泡硫氧镁水泥浇注而成,突破了以往木质地板厚度的局限性,可以根据实际情况定制任意厚度的复合地板;同时也突破了以往木质地板卡扣的局限性,可以在本复合地板上设置复合的卡扣使得拼接缝隙隐而不见。在基体上附着漂亮的木质树皮后会让本发明的复合地板在外观上完全做到了与木质地板一致,安装完后视觉效果与脚感也无较大的差异。相比木质地板,本发明完全解决了防水防火的问题,即使长时间浸泡在水中本复合地板也不会变型;本发明在着火时不仅不燃烧,还是一种阻燃物,防止大火烧穿地板引起地板下的管路燃烧。而且本复合地板本身材料坚硬,一般日常生活中的撞击不会对本复合地板造成影响。本复合地板还具有非常好的隔热效果,配合本复合地板厚度的调节,具有冬暖夏凉的效果。通过发泡硫氧镁水泥作为结合剂避免了木质地板低端胶黏剂毒性大,高端胶黏剂价格贵的问题,彻底的解决了地板环保的问题。本发明复合地板的成本也远低于木质地板,适合大规模的推广利用。
与现有技术相比,本复合地板具有与木质地板相同的质感与脚感,还具有优良的弹性,行走在上面时柔和无噪音,同时还具有木质地板不具有的耐水性、不燃性、无毒性、耐久性等特点。
具体实施方式
下面结合具体实施方式对本发明作进一步详细描述。
实施例1:一种无机材质复合地板制作方法,包括以下几个步骤,步骤A):以重量百分比计,将含有至少85%Na2O·CaO·6SiO2复合硅酸盐的玻璃进行研磨,研磨后得到细度不小于200目的复合硅酸盐粉末,将碳酸盐进行研磨,研磨后的细度不小于200目的碳酸盐粉末。步骤B):以质量百分比计,将95%的复合硅酸盐粉末,5%的碳酸盐粉末混合成原料粉末,在800℃之间对原料粉末进行加热,原料粉末在加热过程中由粉状固相转变成熔融状的液相形成熔融玻璃体,在此过程中熔融玻璃体会释放CO2气体,当熔融玻璃体CO2气体释放完后进行冷却,在冷却的过程中熔融玻璃体开始固化成多孔状态的泡沫玻璃体,把泡沫玻璃体破碎后得到颗粒容重为300kg/m3、颗粒直径5mm~50mm的泡沫玻璃碎块。步骤C):以质量份计,将65份轻烧氧化镁,35份波美度在25°Be'的硫酸镁混合成硫氧镁水泥浆,然后在通入空气的情况下往硫氧镁水泥浆内添加2.5份十八烷基磺酸钠形成容重为650kg/m3的发泡硫氧镁水泥浆体。步骤D):在板状模具中放入泡沫玻璃碎块,放入的泡沫玻璃碎块的颗粒直径需要根据模具内的实际宽度和厚度选择,一般而言颗粒直径短则弹性越好,性能越优良。然后注入硫氧镁水泥浆体,干燥后形成胶体层。板状模具的大小和宽度根据实际情况进行设计调整,模具侧部可以设置卡扣形状一体浇注,也可以在浇注的过程中放入卡扣结构,通过浇注固定。如果需要浇注非常厚的模具,可以分批进行浇注,每次只浇注一定厚度的胶体层,待下层胶体层干燥后在往上浇注,直至全部浇注完成。步骤E):在胶体层上附着树皮层形成复合地板,所述的树皮层厚度在0.5mm~0.6mm之间。
通过本实施例制作出的复合地板抗压强度不小于5Mpa,抗弯强度不小于8Mpa,容重不大于800kg/m3,含水率在10%以下。完全无甲醛释放。
实施例2:一种无机材质复合地板制作方法,包括以下几个步骤,步骤A):以重量百分比计,将含有至少80%Na2O·CaO·6SiO2复合硅酸盐的玻璃进行研磨,研磨后得到细度不小于200目的复合硅酸盐粉末,将碳酸盐进行研磨,研磨后得到细度不小于200目的碳酸盐粉末。步骤B):以质量百分比计,将97%的复合硅酸盐粉末,3%的碳酸盐粉末混合成原料粉末,在850℃之间对原料粉末进行加热,原料粉末在加热过程中由粉状固相转变成熔融状的液相形成熔融玻璃体,在此过程中熔融玻璃体会释放CO2气体,当熔融玻璃体CO2气体释放完后进行冷却,在冷却的过程中熔融玻璃体开始固化成多孔状态的泡沫玻璃体,把泡沫玻璃体破碎后得到颗粒容重为400kg/m3、颗粒直径5mm~50mm的泡沫玻璃碎块。步骤C):以质量份计,将75份轻烧氧化镁,45份波美度在30°Be'的硫酸镁混合成硫氧镁水泥浆,然后在通入空气的情况下往硫氧镁水泥浆内添加3份十八烷基磺酸钠形成容重为700kg/m3的发泡硫氧镁水泥浆体。步骤D):在板状模具中放入泡沫玻璃碎块,放入的泡沫玻璃碎块的颗粒直径需要根据模具内的实际宽度和厚度选择,一般而言颗粒直径短则弹性越好,性能越优良。然后注入硫酸镁水泥浆体,干燥后形成胶体层。板状模具的大小和宽度根据实际情况进行设计调整,模具侧部可以设置卡扣形状一体浇注,也可以在浇注的过程中放入卡扣结构,通过浇注固定。如果需要浇注非常厚的模具,可以分批进行浇注,每次只浇注一定厚度的胶体层,待下层胶体层干燥后在往上浇注,直至全部浇注完成。步骤E):在胶体层上附着树皮层形成复合地板,所述的树皮层厚度在0.5mm~0.6mm之间。
通过本实施例制作出的复合地板抗压强度不小于5.5Mpa,抗弯强度不小于8.2Mpa,容重不大于820kg/m3,含水率在13%以下。完全无甲醛释放。
实施例3:一种无机材质复合地板制作方法,包括以下几个步骤,步骤A):以重量百分比计,将含有至少80%Na2O·CaO·6SiO2复合硅酸盐的玻璃进行研磨,研磨后得到细度不小于200目的复合硅酸盐粉末,将碳酸盐进行研磨,研磨后得到细度不小于200目的碳酸盐粉末。步骤B):以质量百分比计,将95%的复合硅酸盐粉末,5%的碳酸盐粉末混合成原料粉末,在825℃之间对原料粉末进行加热,原料粉末在加热过程中由粉状固相转变成熔融状的液相形成熔融玻璃体,在此过程中熔融玻璃体会释放CO2气体,当熔融玻璃体CO2气体释放完后进行冷却,在冷却的过程中熔融玻璃体开始固化成多孔状态的泡沫玻璃体,把泡沫玻璃体破碎后得到颗粒容重为250kg/m3、颗粒直径5mm~50mm的泡沫玻璃碎块。步骤C):以质量份计,将60份轻烧氧化镁,30份波美度在27.5°Be'的硫酸镁混合成硫氧镁水泥浆,然后在通入空气的情况下往硫氧镁水泥浆内添加2份十八烷基磺酸钠形成容重为600kg/m3的发泡硫酸镁水泥浆体。步骤D):在板状模具中放入泡沫玻璃碎块,然后注入硫氧镁水泥浆体,干燥后形成胶体层。板状模具的大小和宽度根据实际情况进行设计调整,模具侧部可以设置卡扣形状一体浇注,也可以在浇注的过程中放入卡扣结构,通过浇注固定。如果需要浇注非常厚的模具,可以分批进行浇注,每次只浇注一定厚度的胶体层,待下层胶体层干燥后在往上浇注,直至全部浇注完成。步骤E):在胶体层上附着树皮层形成复合地板,所述的树皮层厚度在0.3mm~0.6mm之间。。
通过本实施例制作出的复合地板抗压强度不小于5Mpa,抗弯强度不小于7.8Mpa,容重不大于800kg/m3,含水率在15%以下。完全无甲醛释放。
Claims (4)
1.无机材质复合地板,其特征为,包括胶体层和设置在所述胶体层上的树皮层,所述的胶体层由泡沫玻璃碎块作为基体、发泡硫氧镁水泥作为浆体胶结而成,其通过以下几个步骤所得:步骤A):以重量百分比计,将含有至少80%Na2O·CaO·6SiO2复合硅酸盐的玻璃进行研磨,研磨后得到细度不小于200目的复合硅酸盐粉末,将碳酸盐进行研磨,研磨后得到细度不小于200目的碳酸盐粉末;步骤B):以质量百分比计,将95%~97%的复合硅酸盐粉末,3%~5%的碳酸盐粉末混合成原料粉末,在800℃至850℃之间对原料粉末进行加热,原料粉末在加热过程中由粉状固相转变成熔融状的液相形成熔融玻璃体,在此过程中熔融玻璃体会释放CO2气体,当熔融玻璃体CO2气体释放完后进行冷却,在冷却的过程中熔融玻璃体开始固化成多孔状态的泡沫玻璃体,把泡沫玻璃体破碎后得到颗粒容重为250kg/m3~350kg/m3、颗粒直径5mm~50mm的泡沫玻璃碎块;步骤C):以质量份计,将60份~70份轻烧氧化镁,30份~40份波美度在25°Be'~30°Be'之间的硫酸镁混合成硫氧镁水泥浆,然后在通入空气的情况下往硫氧镁水泥浆内添加2份~3份十八烷基磺酸钠形成容重为600kg/m3~700kg/m3的发泡硫酸镁水泥浆体;步骤D):在板状模具中放入泡沫玻璃碎块,然后注入硫氧镁水泥浆体,干燥后形成胶体层;步骤E):在胶体层上附着树皮层形成复合地板。
2.根据权利要求1所述的无机材质复合地板,其特征为,在步骤B中,所述泡沫玻璃碎块容重为300kg/m3。
3.根据权利要求1所述的无机材质复合地板,其特征为,在步骤C中,发泡硫酸镁水泥浆体容重为650kg/m3。
4.根据权利要求1所述的无机材质复合地板,其特征为,所述的树皮层厚度在0.3mm~0.6mm之间。
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